Form-less electronic device assemblies and methods of operation

ABSTRACT

Improved form-less electronic apparatus and methods for manufacturing the same. In one exemplary embodiment, the apparatus comprises a shape-core inductive device having a bonded-wire coil which is formed and maintained within the device without resort to a bobbin or other form(er). The absence of the bobbin simplifies the manufacture of the device, reduces its cost, and allows it to be made more compact (or alternatively additional functionality to be disposed therein). One variant utilizes a termination header for mating to a PCB or other assembly, while another totally avoids the use of the header by directly mating to the PCB. Multi-core variants and methods of manufacturing are also disclosed.

PRIORITY CLAIM

This application is a continuation of and claims priority to co-ownedU.S. patent application Ser. No. 12/572,168 of the same title, filedOct. 1, 2009, to issue Jan. 25, 2011 as U.S. Pat. No. 7,876,189, whichis a divisional of and claims priority to co-owned Ser. No. 10/885,868,filed Jul. 6, 2004, now U.S. Pat. No. 7,598,837 entitled “FORM-LESSELECTRONIC DEVICE AND METHODS OF MANUFACTURING”, issued on Oct. 6, 2009and which claims priority benefit of co-owned U.S. Provisional PatentApplication Ser. No. 60/485,801 of the same title filed Jul. 8, 2003,each of which is incorporated herein by reference in its entirety.

COPYRIGHT

A portion of the disclosure of this patent document contains materialthat is subject to copyright protection. The copyright owner has noobjection to the facsimile reproduction by anyone of the patent documentor the patent disclosure, as it appears in the Patent and TrademarkOffice patent files or records, but otherwise reserves all copyrightrights whatsoever.

BACKGROUND OF THE INVENTION

1. Field of Invention

The present invention relates generally to electronic elements andparticularly to an improved design and method of manufacturing miniatureelectronic components including transformers and inductive devices(e.g., “choke coils”) without a bobbin or other forming component.

2. Description of Related Technology

As is well known in the art, inductive components are electronic deviceswhich provide the property of inductance (i.e., storage of energy in amagnetic field) within an alternating current circuit. Inductors are onewell-known type of inductive device, and are formed typically using oneor more coils or windings which may or may not be wrapped around amagnetically permeable core. So-called “dual winding” inductors utilizetwo windings wrapped around a common core.

Transformers are another type of inductive component that are used totransfer energy from one alternating current (AC) circuit to another bymagnetic coupling. Generally, transformers are formed by winding two ormore wires around a ferrous core. One wire acts as a primary winding andconductively couples energy to and from a first circuit. Another wire,also wound around the core so as to be magnetically coupled with thefirst wire, acts as a secondary winding and conductively couples energyto and from a second circuit. AC energy applied to the primary windingscauses AC energy in the secondary windings and vice versa. A transformermay be used to transform between voltage magnitudes and currentmagnitudes, to create a phase shill, and to transform between impedancelevels.

Ferrite-cored inductors and transformers are commonly used in modernbroadband telecommunications circuits to include ISDN (integratedservices digital network) transceivers, DSL (digital subscriber line)modems and cable modems. These devices provide any number of functionsincluding shielding, control of longitudinal inductance (leakage), andimpedance matching and safety isolation between broadband communicationdevices and the communication lines to which they are connected.Ferrite-core inductive device technology is driven by the need toprovide miniaturization while at the same time meeting performancespecifications set by chip-set manufactures and standards bodies such asthe ITU-T. For example, in DSL modems, microminiature transformers aredesired that can allow a DSL signal to pass through while introducing aminimal THD (total harmonic distortion) over the DSL signal bandwidth.As another example, dual-winding inductors can be used in telephone linefilters to provide shielding and high longitudinal inductance (highleakage).

“Shaped” Devices

A common prior art ferrite-cored inductive device is known as theEP-core device. EP and similar devices are well known in the prior art.For example, U.S. Pat. No. 5,489,884 to Heringer, et al. issued Feb. 6,1996 and entitled “Inductive Electric Component” discloses an inductiveelectric component including a coil body having coil body flangesdefining a winding space, and contact pin strips integrally formed ontothe coil body flanges, the contact pin strips having extensions andhaving free ends with undercuts formed therein being limited outwardlyby the extensions. U.S. Pat. No. 5,434,493 to Woody, et al. issued Jul.18, 1995 and entitled “Fixed core inductive charger” discloses anEP-core device, as well as other shaped core devices, including EE andRS devices. Other similar well-know devices include inter alia so-calledEF, ER, RM, and pot core devices. See, e.g., the pot core device isdescribed in U.S. Pat. No. 5,952,907 to McWilliams, et al. issued Sep.14, 1999 and entitled “Blind Hole Pot Core Transformer Device.”

FIG. 1 illustrates a representative prior art EP transformerarrangement, and illustrates certain aspects of the manufacturingprocess therefore. The EP core of the device 100 of FIG. 1 is formedfrom two EP-core half-pieces 104, 106, each having a truncatedsemi-circular channel 108 formed therein and a center post element 110,each also being formed from a magnetically permeable material such as aferrous compound. As shown in FIG. 1, each of the EP-core half-pieces104, 106 are mated to form an effectively continuous magneticallypermeable “shell” around the windings 112, the latter which are woundaround a spool-shaped bobbin 109 which is received on the center postelement 110. The precision gap in ground on the ferrite post 110 can beengineered to adjust the transfer function of the transformer to meetcertain design requirements. When the EP core device is assembled, thewindings 112 wrapped around the bobbin 109 also become wrapped aroundthe center post element 110. This causes magnetic flux to flow throughthe EP core pieces when an alternating current is applied to thewindings. Once the device is assembled, the outer portion of the EPcores self-enclose the windings to provide a high degree of magneticshielding. The ferrous material in the core is engineered to provide agiven flux density over a specified frequency range and temperaturerange.

The bobbin 109 includes a terminal array 114 (aka “header”) generallymounted to the bottom of the device 100, with the windings 112penetrating through the truncated portions 116 of the half-pieces 104,106, the terminal array 114 being mated to a printed circuit board (PCB)or other assembly. Margin tape (not shown) may also be applied atop theouter portions of the outer winding 112 for additional electricalseparation if desired.

For each core shape and size, various differing bobbins are available.The bobbins themselves (in addition to the other elements of the parentdevice) have many different characteristics; they can provide differingnumbers of pins/terminations, different winding options, different finalassembly techniques, surface mount versus through-hole mount, etc. Forexample, U.S. Pat. No. 6,587,023 to Miyazaki, et al. issued Jul. 1, 2003and entitled “Electromagnetic Induction Device” discloses a flat bobbinwith coaxially aligned through-holes. U.S. Pat. No. 5,350,980 to Dye, etal. issued Sep. 27, 1994 and entitled “Nonlinear Inductor with MagneticField Reduction” discloses, inter alia, a dumbbell-shaped ferrite bobbincarrying an inductive coil.

Magnet wire is commonly used to wind transformers and inductive devices(such as inductors and transformers, including the aforementionedEP-type device). Magnet wire is made of copper or other conductivematerial coated by a thin polymer insulating film or a combination ofpolymer films such as polyurethane, polyester, polyimide (aka“Kapton™”), and the like. The thickness and the composition of the filmcoating determine the dielectric strength capability of the wire. Magnetwire in the range of 31 to 42 AWG is most commonly used inmicroelectronic transformer applications, although other sizes may beused in certain applications.

The prior art EP and similar inductive devices described above haveseveral shortcomings. A major difficulty with EP devices is thecomplexity of their manufacturing process, which gives rise to a highercost. The use of a bobbin (also called a “form” or “former”) increasesnot only the cost, but size and complexity of the final device, sincethe bobbin is retained within the device upon completion of themanufacturing process. The bobbin consumes space within the device whichcould be used for other functionality, or conversely eliminated to givethe final device a smaller size and/or footprint.

Also, the EP core half pieces themselves are relatively costly to moldand produce. For example, by the time the EP transformer is assembledand tested, its volume production cost is high (currently ranging fromapproximately $0.50 to −$0.70). It would be desirable to produce adevice having performance characteristics at least equivalent to thoseof an EP transformer, but at a significantly lower cost.

Yet a further disability of “headered” shaped core devices such as thatof FIG. 1 is the use of the header or terminal array 114 itself. Thiscomponent adds additional cost and manufacturing steps, and at minimumincreases the vertical profile of the device 100. In certainapplications, it would be desirable to utilize a lower profileconfiguration without a header if possible.

Bonded Wire

Bonded wire is a well-established product/process that is used toproduce so-called “air coils”. Air coils themselves are inductors, andare typically use in RFID tags, voice coils, sensors, and the like. Thematerials and manufacturing equipment for producing bonded wire arecommercially available from a variety of sources known to the artisan ofordinary skill.

Bonded wire is essentially an enamel-coated wire having additionalcoating applied (by either the wire vendor or the device manufacturer)to the outer surfaces of the enamel. Generally, during winding, thebonded wire coating may be activated (normally by heat, although othertypes of processes including radiation flux, chemical agents, and soforth) to cause the coated wires to stick/bond together. This approachprovides certain benefits and cost economies in the context ofelectronic component production.

Accordingly, there is a need for an improved electronic device, and amethod of manufacturing the device, that does not require use of abobbin or other form(er). Such an improved device would ideally utilizeexisting and well understood technologies in place of thebobbin/form(er) in order to simplify the manufacturing process andfurther reduce cost, yet still maintain the desirable electrical andphysical properties of its bobbined counterpart while reducing theoverall size and/or footprint of the device.

Furthermore, for certain applications, it would be highly desirable toobviate the header (terminal array) of the prior art from the shapedcore device altogether.

SUMMARY OF THE INVENTION

The present invention satisfies the aforementioned needs by providingimproved electronic inductive devices, and methods of manufacturing thesame.

In a first aspect of the invention, an improved form-less electronicdevice is disclosed. The device generally comprises a core and at leastone winding, the at least one winding being formed and disposed withinthe device without use of an internal bobbin. In one exemplaryembodiment, the device comprises a bonded-wire coil formed to residewithin a shaped core, the bonded wire of the coil obviating the use ofan internal bobbin or other comparable structure. A termination elementis disposed on the bottom of the device to permit termination of coilwindings to the parent assembly (e.g., PCB).

In a second aspect of the invention, a multi-core device is disclosed.In the exemplary embodiment, the multi-core device comprises a pluralityof form-less electronic inductive devices as described above disposedwithin a common termination header in end-to-end (or side-by-side)orientation, thereby economizing on PCB footprint. Pins with commonsignals are optionally consolidated, thereby reducing the requirednumber of terminal leads as well.

In a third aspect of the invention, a termination header for use interminating a form-less inductive device is disclosed. In oneembodiment, the termination header comprises a molded assembly withinset SMT terminals which attaches to a single core of the device usingstandard gluing techniques. In another embodiment, the header is adaptedto receive a plurality of cores adjacent one another.

In a fourth aspect of the invention, a method of manufacturing theabove-referenced form-less electronic devices is disclosed. The methodgenerally comprises: providing a termination header; providing a shapedcore separated into at least two elements; providing a bonded windingcomprising wire having ends; forming a shaped core assembly by disposingthe winding within the core components such that the ends are exposed;coupling the shaped core assembly with a termination element having aplurality of terminals; and terminating the ends of said winding to onesof the terminals.

In a fifth aspect of the invention, an improved “direct assembly”form-less device is disclosed. In one embodiment, the device comprises aform-less inductive device as previously described, yet which matesdirectly with the parent assembly (e.g., PCB), thereby obviating thetermination header. The free ends of the windings protrude from thedevice through an aperture formed in the underlying assembly. The endsare soldered to conductive pads present on the PCB substrate.

In a sixth aspect of the invention, a method of manufacturing theform-less and header-less inductive device previously described isdisclosed. The method generally comprises: providing a shaped coreseparated into at least two elements; providing at least one length ofwire having ends; forming the wire into a core winding having aplurality of turns, also comprising treating the wire so as to form theturns into a substantially unitary component; and disposing the windingwithin the core elements such that the ends of said winding are exposedfor termination. In one exemplary embodiment, the wire comprisesthermally activated bonding wire which is wound around a mandrel andthen heated, thereby obviating the bobbin. The assembled device is thendirect-assembled onto the PCB or other device as described above.

In a seventh aspect of the invention, a self-leaded electrical deviceadapted for surface mounting is disclosed, generally comprising abobbin-less inductive element and a self-leaded termination elementcoupled to the inductive element, the self-leaded termination elementcomprising a plurality of terminal elements each adapted to receive atleast one of the winding ends of the inductive winding thereon so as topermit surface mounting. In one exemplary embodiment, the terminationelement comprises a molded plastic header with terminal posts aroundwhich the core windings are wrapped.

In an eighth aspect of the invention, a low profile, low cost electronicassembly, is disclosed, generally comprising: a PCB having a firstaperture formed therein and a plurality of contact pads formed thereon;and a bobbin-less inductive device having a shaped core with a secondaperture formed therein and a winding having a plurality of free ends,the first and second apertures substantially communicating with eachother such that the free ends pass through both apertures and are eachterminated to ones of the contact pads. At least a portion of thewinding is received within the second aperture, thereby permitting theinductive device to be reduced in overall (installed) height.

In a ninth aspect of the invention, a reduced footprint multi-coreelectronic assembly is disclosed. The assembly generally comprises aplurality of bobbin-less and header-less inductive devices disposed insubstantially mated and in-line configuration. In one exemplaryembodiment, the devices are disposed in adjacent, juxtaposed(side-by-side) fashion and direct-assembled to the parent device (e.g.,PCB), thereby occupying the smallest possible footprint.

BRIEF DESCRIPTION OF THE DRAWINGS

The features, objectives, and advantages of the invention will becomemore apparent from the detailed description set forth below when takenin conjunction with the drawings, wherein:

FIG. 1 is an exploded view of a typical prior art EP transformer designhaving a two-piece EP core and bobbin, illustrating the componentsthereof.

FIG. 2 a is an exploded perspective view of a first exemplary embodimentof the improved electronic device of the present invention.

FIG. 2 b is a side plan view of the device of FIG. 2 a.

FIG. 2 c is a cross-sectional view of the device of FIG. 2 a, takenalong line 2 c-2 c.

FIG. 2 d is a logical flow diagram illustrating one exemplary method ofmanufacturing the device of FIGS. 2 a-2 c.

FIG. 2 e is a top elevational view of a first exemplary embodiment of aself-leaded improved electronic device of the present invention.

FIG. 2 f is an end elevational view of a second exemplary embodiment ofa self-leaded improved electronic device of the present invention.

FIG. 3 is a perspective view of second embodiment of the form-lessdevice of the present invention, having multiple inductive cores and aunitary termination header.

FIG. 4 is a top perspective view of another embodiment of the form-lesselectronic device of the invention adapted for direct assembly to aparent device (e.g., PCB).

FIG. 4 a is a bottom perspective view of the device of FIG. 4,illustrating one exemplary termination scheme used therewith.

FIG. 4 b is a front plan view of another exemplary configuration of a“direct assembly” inductive device according to the invention, for useon PCBs or other equipment not having an aperture or recess.

FIG. 4 c is a top plan view of a typical prior art multi-corearrangement disposed on a PCB, illustrating its comparatively largefootprint.

FIGS. 4 d and 4 e are top and bottom plan views, respectively of anexemplary “ganged” multi-core arrangement (on a PCB) according to thepresent invention, illustrating its reduced footprint as compared tothat of the prior art arrangement of FIG. 4 c.

FIG. 5 is a logical flow diagram illustrating one exemplary method ofmanufacturing the device of FIGS. 4-4 a.

FIG. 6 a is an exploded perspective view of another embodiment of theinductive device of the invention, illustrating the use of a substrateand interface element.

FIG. 6 b is a perspective view of the device of FIG. 6 a fullyassembled.

FIG. 6 c is an exploded perspective view of yet another embodiment ofthe inductive device of the invention, illustrating a simplifiedstructure without an interface element.

FIG. 6 d is an exploded perspective view of still another embodiment ofthe inductive device of the invention.

FIGS. 6 e and 6 f illustrate still another embodiment of the inductivedevice of the invention.

DETAILED DESCRIPTION OF THE INVENTION

Reference is now made to the drawings wherein like numerals refer tolike parts throughout.

As used herein, the term “inductive device” refers to any device usingor implementing induction including, without limitation, inductors,transformers, and inductive reactors (or “choke coils”.

As used herein, the terms “bobbin” and “form” (or “former”) are used torefer to any structure or component(s) disposed on or within aninductive device which helps form or maintain one or more windings ofthe device.

As used herein, the term “signal conditioning” or “conditioning” shallbe understood to include, but not be limited to, signal voltagetransformation, filtering and noise mitigation, signal splitting,impedance control and correction, current limiting, and time delay.

As used herein, the term “digital subscriber line” (or “DSL”) shall meanany form of DSL configuration or service, whether symmetric orotherwise, including without limitation so-called “G.lite” ADSL (e.g.,compliant with ITU G.992.2), RADSL: (rate adaptive DSL), VDSL (very highbit rate DSL), SDSL (symmetric DSL), SHDSL or super-high bit-rate DSL,also known as G.shdsl (e.g., compliant with ITU Recommendation G.991.2,approved by the ITU-T February 2001), HDSL: (high data rate DSL), HDSL2:(2nd generation HDSL), and IDSL (integrated services digital networkDSL), as well as In-Premises Phoneline Networks (e.g., HPN).

Overview

In one primary aspect, the present invention provides improvedbobbin-less electronic apparatus and methods for producing the same. Theelectronic apparatus may be used in any number of electrical circuitsincluding for example those used for signal conditioning or in DSLcircuits. One significant benefit of winding the coil independent of abobbin (or “former”) is that the space normally taken up by the bobbininside the device can be utilized for additional functionality, or thedesign made smaller in size and/or footprint.

Specifically, more winding space inside the device allows any of thefollowing (or combination thereof) to be utilized in the design: (i)more winding turns can be used on a given design, therefore moreinductance/performance can be achieved in a given form factor (i.e.,higher winding density); (ii) alternatively, heavier gauge wire can beused and yet maintain the same number of turns, thereby providing otherelectrical performance benefits; (iii) the performance of a given designusing a bobbin can be achieved in a smaller “bobbinless” design. Smallerdevices are generally lower cost. In addition to the cost benefit,smaller size for a given performance also offers the end applicationspace and footprint reduction benefits that can be very attractive inhigh-density applications.

In addition to the significant electrical design benefits, bobbinlessdesigns offer other significant advantages, including the flexibility toterminate the windings of the device before or after core assembly, andthe use of different termination approaches which take full advantage ofthe bobbinless design construction and manufacturing methodology.

Exemplary Apparatus

It will be recognized that while the following discussion is cast interms of an exemplary shaped core transformer, the invention is equallyapplicable to other inductive devices (e.g., inductors) and coreconfigurations. Conceivably, any device having a plurality of windingturns and requiring electrical insulation may benefit from theapplication of the approach of the present invention. Accordingly, thefollowing discussion of the shaped core transformer is merelyillustrative of the broader concepts.

Referring now to FIGS. 2 a-2 c, an exemplary embodiment of a bobbinless(form-less) inductive device (e.g. shaped core transformer) isdescribed. As shown in FIGS. 2 a-2 c, the device 200 generally comprisesa core element 202, wound coil 204, and a termination element or header206. The core element in the illustrated embodiment is “E-shaped” withan oval-shaped center leg 203; it will be recognized that variousdifferent shapes may be used (such as EF, EE, ER, and RM, and even potcore), however. In addition, it will be recognized that the core elementand the wound coil together may be at any angle relative to the header.For example, FIG. 6 illustrates one embodiment where the “E-shaped” coreelement 602 a, 602 b and wound coil 604 is positioned such that thecore's open plane is perpendicular to the printed circuit board plane onwhich the header is positioned. The core element 202 comprises twopieces 202 a, 202 b of similar configuration. The core is fashioned froma magnetically permeable material such as a soft ferrite or powderediron, as is well known in the electrical arts. The manufacture andcomposition of such cores is well understood, and accordingly is notdescribed further herein. The cores are assembled onto the wound coil204 and the termination element 206.

In the illustrated embodiment, an adhesive is used to mate the core 202to the molded polymer termination element 206, due primarily to ease ofmanufacturing and low cost. However, other techniques for fastening thetwo components (i.e., core 202 and termination element 206) together maybe utilized. For example, metallic “spring” clips of the type well knownin the art may be used. Alternatively, a frictional arrangement can beused as well, such as where two side risers (not shown) disposed lateralto the outer sides of the core elements 202 a, 202 b are formed as partof the termination element 206; the assembled core 202 is disposed atopthe termination element 206 and then forced into frictional cooperationwith the risers to maintain the core 202 in stationary position on theelement. As yet another option, the core portions 202 a, 202 b may becemented or bonded together, and the wires of the core in effectstretched taught and terminated (e.g., wire wrapped and/or soldered) tothe terminals 210 of the element 206. Hence, the terminated wires act tomaintain tension on the wound coil 204 (and therefore the core 202),thereby acting to maintain the core assembly in communication with thetermination element 206. Different combinations of the foregoing mayalso be used as desired.

The termination element 206 includes a plurality (e.g., eight) terminals210 for physical and electrical mating to another device, such as a PCBor the like. These terminals 210 may be of literally any configuration,including for example, substantially rectangular cross-section adaptedfor surface mount (SMT), circular or elliptical cross-section forthrough-hole mounting, ball-grid array, etc. They may also be notched orshaped to facilitate wire wrapping if desired. Furthermore, it will beappreciated that the termination element 206 may comprise a self-leadedarrangement (not shown) of the type described in co-owned U.S. Pat. No.5,212,345 to Gutierrez issued May 18, 1993 entitled “Self leaded surfacemounted coplanar header”, or U.S. Pat. No. 5,309,130 to Lint issued May3, 1994 and entitled “Self leaded surface mount coil lead form”, both ofwhich are incorporated herein by reference in their entirety. Forexample, in one embodiment, the termination element 206 is a moldedpolymer device having eight (8) self-leading terminals formed therein,upon which various of the conductors of the coil 204 are wound. FIG. 2 eshows a first embodiment of an electronic device comprising self-leadedtermination elements 250 according to the principles of the presentinvention. FIG. 2 f shows a second embodiment of an electronic devicecomprising self-leaded termination elements 250 according to theprinciples of the present invention.

It is further recognized that the termination element 206 may take anynumber of different forms or configurations in terms of its shape. Forexample, the termination element 206 may comprise a substantiallysquare, circular, or polygonal form, depending on the needs of theparticular application. Additionally, the exact placement of theterminals 210 within the element 206 can be optimized based upon circuitplacement and mounting considerations at the system level.

Also, if desired, the termination element may be obviated altogetherthrough, e.g., the approach described subsequently herein with respectto FIGS. 4 and 4 a, or alternatively direct bonding of the conductiveterminals 210 to the core itself.

As shown in FIG. 2 a, the wound coil 204 comprises one or more windingsof wire which, when formed, is inserted between the core portions 202 a,202 b and into the termination element 206. The coil windings consist ofbonded wire of the type described previously herein, and is woundindependent of an internal bobbin or form(er), such as on a removabledie, winding mandrel or steel former. The shape of the coil is definedby the dimensions of the winding mandrel. In one exemplary embodiment,the winding mandrel comprises a polished steel shaft with a centrallydisposed groove or recess. The groove/recess if formed by the extensionof a selectively retractable pin or shaft. The bonded wire is held by afirst of two small radial pins or dowels disposed adjacent the groove ofthe shaft. The bound wire source (e.g., spool) is then laterally alignedover the groove, and the shaft rotated to build up the winding coil 204.Once the winding is complete, the terminal end of the wire is thenbrought and held by a second radial pin disposed adjacent the other sideof the groove. The winding is then heated (such as by blowing hot airover the mandrel, or heating the mandrel itself, etc.) so that the wiresof the coil are bonded.

It will be recognized that many variations of this approach exist, suchas where the shaft (mandrel) is stationary and the wire source rotatedaround the mandrel. Such winding techniques are well known in themechanical arts, and accordingly not described further herein.

Additionally, it will be appreciated that different winding lay patternsmay be used in order to achieve certain design objectives. For example,a substantially parallel lay pattern may provide the tightest spatialpacking, thereby reducing the size of the winding as a whole.Alternatively, other lay patterns may provide the most desirableelectrical and/or magnetic performance for certain applications. Allsuch variations will be recognized by those of ordinary skill.

When the single or multiple winding has been completed, the retractablecenter pin on the winding mandrel (which forms the groove) is withdrawnallowing the formed and bonded coil to be removed, or drop due togravity, and winding of a new coil can commence again.

In the exemplary embodiment, the bonded wire comprises 35 AWG-42 AWGbondable wire manufactured by the Bridgeport Insulated Wire Company ofBridgeport, Conn., although other manufacturers, configurations andsizes of wire may be used. The wire comprises round copper magnet wirewith a polyurethane base coating. The polyurethane base coat has apolyamide (Kapton) and self-bonding overcoat. The wire of theillustrated embodiment complies with the NEMA MW29-C and IEC 317-35international standards for wire, although this is not required. It willbe understood, however, that suitable wire may be purchased and thensubsequently coated (whether before, during, or after the mandrelforming process previously described) in order to produce the desiredwindings 204.

It will be recognized that the foregoing “form-less” wire bondingprocess may be applied to (i) a single continuous winding; (ii) multiplewindings bonded into a unitary physical group or structure; or (iii)single or multiple windings bonded into two or more discrete groupswhich may or may not themselves ultimately be bonded together using theaforementioned bonding techniques or others. Hence, the presentinvention contemplates various winding/bonding configurations which maybe driven for example by dielectric withstand requirements, the need formultiple windings within the same core, and so forth.

Furthermore, while bonded wire is preferred, the device 200 may alsoutilize a wound coil formed and coated as described generally inco-owned U.S. Pat. No. 6,642,827 issued Nov. 4, 2003 and entitled“Advanced Electronic Miniature Coil and Method of Manufacturing”, whichis also incorporated herein by reference in its entirety. Specifically,a Parylene coating is applied to a plurality of individual wires formedinto a layer or group using for example a vapor or vacuum depositionprocess. Parylene is chosen for its superior properties and low cost;however, certain applications may dictate the use of other insulatingmaterials. Such materials may be polymers such as for examplefluoropolymers (e.g., Teflon, Tefzel), polyethylenes (e.g., XLPE),polyvinylchlorides (PVCs), or conceivably even elastomers. Additionally,dip or spray-on coatings may be used to form the wound coil 204 of theillustrated invention.

Note that in the present embodiment, the free ends 220 of the windings(see FIG. 2 c) are stripped of insulation prior to winding, afterwinding, or during soldering (so-called “solder stripping”), usingtechniques well known in the art. This stripping facilitates theformation of good electrical contacts with the terminals 210 to whichthe free ends 220 are mated.

Because the coil is wound independent of an internal bobbin or form(er),additional space inside the device 200 is available in its finalassembled configuration. This additional space permits the inclusion ofgreater turns on a given core design, therefore advantageouslyincreasing the inductance and/or performance of a given shaped core.Conversely, the additional space created by obviating the bobbin allowsthe use of heavier gauge wire, while maintaining the same number ofturns, thereby providing other electrical performance benefits such asreduced DC resistance and insertion loss.

Furthermore, the additional space may be used to decrease the overallsize and/or footprint of the device 200, as well as its weight. Smallercores not only have a cost benefit (due to use of less material), butalso offer the end application space benefits, which is especiallyattractive in high-density applications. For example, the larger priorart (bobbined) counterpart device having the required electricalperformance simply may not fit in certain applications. It can beappreciated that these design variations, as well as other designvariations available uniquely due to the “bobbin-less” or form-lessfeature of the invention, may be used independently or in combinationwith each other.

FIG. 2 d illustrates one exemplary method 270 of manufacturing theinductive device 200 of FIGS. 2 a-2 c. It will be appreciated that whilevarious steps are described in terms of forming or manufacturingcomponents of the inductive device 200, such steps may be obviated byalternatively procuring the pre-manufactured component from a thirdparty.

As shown in FIG. 2 d, the method 270 generally comprises first forming atermination header 206 (step 272), including forming the terminals 210and disposing them within the header (step 274). Next, a shaped core 202is provided, separated into its component elements 202 a, 202 b (step276). Bonded wire is next provided in sufficient quantity (step 278).Per step 280, the bonded wire is then formed on an external form, andcured (e.g., heated, exposed to chemical agents, irradiated, etc.). Thecured coil 204 is then removed from the form and prepared, whichincludes properly positioning the free ends of the windings and shippingthem if required (step 282). The prepared coil is then disposed betweenthe core halves, the latter being optionally bonded together if desired(step 284). The assembled core is then disposed onto the terminationelement 206 using adhesive (step 286), and the free ends 220 terminatedto their respective terminals 210 (step 288). The device is thenoptionally tested per step 290.

Referring now to FIG. 3, another embodiment of the inductive device ofthe present invention is described. FIG. 3 shows a device assembly 300having multiple inductive devices 301 (e.g., four) ganged together in anarray which is disposed within a combined termination header 306. In theillustrated embodiment, the devices 301 are disposed with their longerdimension being co-linear, although other orientations (e.g.,side-by-side) and array formations may be used. The multiple coreassembly 300 of FIG. 3 provides many advantages over single coreassemblies. Specifically, multiple cores 301 on a single header 306reduce and/or eliminate the spacing or stand-off required between coreson a single header in conventional designs. This spacing representswasted PCB area, since the individual devices can be placed only soclose to one another. The space-conserving benefits of the invention aremagnified as greater numbers of devices are ganged; e.g., eight, twelve,and so forth.

Multiple core termination headers 306 also reduce the number ofterminations to the printed circuit board (PCB), as common pins orterminals 310 on a discrete design may be consolidated onto singletermination points in a multiple core header design such as that of FIG.3.

Furthermore, there are economies associated with the fabrication of asingle termination header 306 as opposed to two or more discrete ones.

Direct Assembly Soldering Termination Method

In addition to the foregoing design benefits, the form-less inductivedevices of the present invention provide the ability to terminate thewires before or after core assembly, rather than requiring thetermination of wires to pins on the bobbin prior to core assembly asrequired under the prior art. The flexibility to terminate the wiresbefore or after coil assembly not only allows for flexibility within themanufacturing process (e.g., the permutation of the order of steps inmaking the device 200), but also permits at least two distincttermination approaches: (i) the use of termination elements (headers) asdescribed with respect to FIGS. 2 a-2 c above; and (ii) direct assemblysoldering. The latter technique is now described in detail with respectto FIGS. 4 and 4 a. While the following discussion is cast in terms ofEP-type cores, it can be appreciated that the invention is in no waylimited to such core designs.

As shown in FIGS. 4 and 4 a, the direct assembly soldering approach ofthe present invention advantageously eliminates the need for bobbin(s)or header(s). In this method, the inductive device 400 is directlymounted and/or assembled onto the final assembly or parent device, whichmay be for example a PCB 403 or other electronic component. In theexemplary embodiment, the assembly or parent device includes one or moreapertures 405 formed therein adapted to receive the free conductor ends420 of the device coil 404. The inductive device 400 may be glued orbonded to the PCB 403 or other assembly to which it is mounted as shownin FIG. 4, or alternatively friction-fit, such as by providing the outerperiphery of the core portions 402 a, 402 b with a tapered or ridgedconstruction (not shown), such that the device 400 in effect “snaps”into the PCB aperture 405. Yet other techniques for maintaining thedevice 400 in a substantially constant orientation with respect to theparent assembly 403 may be used as well, such as dowel pins, clips, etc.

As shown in FIG. 4 a, the free ends 420 of the coil windings are broughtthrough the aperture 405 and terminated directly to PCB contact pads 450disposed on the underside 417 of the PCB 403. In the illustratedembodiment, this termination comprises soldering of the free ends 420 tothe pads 450 (such as via a hand or wave soldering process), althoughother approaches for termination may also be used. It will be furtherappreciated that the invention is in no way limited to the use ofcontact pads 450 such as those shown in FIG. 4 a; raised or embeddedterminals, pins, etc. may be used as well consistent with the invention.The illustrated embodiment, however, has the advantage of simplicity andease of manufacture. For example, the depth of the coil 404 in theaperture 405 can be adjusted as desired (whether through device design,PCB thickness, or use of an intervening spacer, not shown) to permit useof a wave soldering process which is highly efficient in providing masstermination of electrical contacts. To this end, the interior edges 452of the aperture 405 can be notched if desired (not shown) in order toretain the routed free winding ends 420 in the desired orientation withrespect to the pads 450 before such mass soldering is performed.

It will also be appreciated that while the embodiment of FIGS. 4 and 4 autilizes pads 450 disposed on the disengaged or underside of the PCB403, such pads may also be disposed on the upper (engaged) side 425(“same side”) of the PCB 403. In one embodiment (FIG. 4 b), the freeends 420 of the windings are simply routed out from under the device 400within the thickness of the adhesive/bonding agent 470 applied betweenthe device 400 and PCB 403 (i.e., the adhesive is applied in sufficientthickness to permit insulated routing of the leads to pads 450 disposedon the upper side 425. In another embodiment, the leads 420 are routedout through notches formed in the core elements 402 a, 402 b. Otherapproaches may be used as well.

Similarly, it will be recognized that the “same side” pad arrangementdescribed above may be used with or without the PCB aperture or recess405 previously discussed. For example, as shown in FIG. 4 b, the coreelements 402 may be configured such that the winding (when assembled)does not protrude below the plane of the base of the core elements,thereby obviating the need for such recess or aperture 405. Thisapproach, however, makes the overall installed height of the device 400on the PCB (or other device) somewhat higher than if the recess/aperture405 is utilized. This “aperture-less” configuration, however, may bedesirable in cases where the PCB or other equipment to which the device400 is mounted does not (or cannot) have apertures 405.

Note also that when mounted to a substrate or PCB, at least portions ofthe inductive device(s) 400 of the present invention may also optionallybe encapsulated using an epoxy or polymer encapsulant (such as silicone)as is well known in the art. The devices may also be shielded againstEMI as is well known in the art, such as by using a well known tin ormetallic Faraday shield.

The foregoing “direct assembly” approach exemplified in FIGS. 4-4 a notonly eliminates the cost of both a bobbin and termination header 206 inthe device 400 (thereby providing an appreciably simpler and less costlydevice for the same electrical performance), but also advantageouslyreduces the overall installed height of a given inductive device design.The approach of FIG. 4 b similarly has no bobbin or header, yet ineffect trades greater vertical height for the absence of a PCB apertureor recess to accommodate the lower portion of the winding.

It will also be recognized that the direct assembly approach generallydescribed above can be used with multiple cores, akin to theconfiguration of FIG. 3 previously discussed. Specifically, multiplecores can be “ganged” together or placed in side-by-side fashion on theparent device (e.g., PCB) so as to minimize the footprint used by thesedevices. The devices 400 may be physically coupled together if desired(not shown), such as by bonding them together via adhesive or the like,using a metallic clip arrangement, using a molded plastic frame whichholds the devices in constant relationship, etc. As yet anotheralternative, the left and right core pieces 402 a, 402 b for theinterior devices can be fabricated as a unitary component (i.e., a leftcore piece of one device 400 which has a right core piece for theimmediately adjacent device 400 as an integral part thereof), with thetwo end core pieces of the assembly being of the type shown in FIG. 4.In this fashion, when the cores are assembled, the individual devices400 are inherently physically attached.

Under prior art approaches to multiple shaped cores (FIG. 4 c), each ofthe bobbined and headered EP cores would need to be spaced somewhat fromone another to prevent interference between their footprints (e.g.,surface mount terminals). Contrast the exemplary “direct assembly”configuration of the present invention (FIGS. 4 d and 4 e), wherein theindividual devices 400 may be literally mated with one another, eitherside-by-side as in FIG. 4 d, or end-to-end (not shown). This reduces theoverall footprint of the aggregated devices 400 (whether in length asshown in FIG. 4 e, or width when the devices are disposed end-to-end).

Furthermore, the aperture-less approach of FIG. 4 b can be implementedin a multi-device assembly akin to that of FIGS. 4 d and 4 e (exceptwith no PCB apertures 405), again trading greater vertical height forthe absence of the apertures/recesses.

Referring now to FIG. 5, a method 500 of direct assembly of EP cores isdescribed in detail. In the first step 502, the process previouslydescribed with respect to FIG. 2 d herein is utilized to form the coreof the device (specifically, steps 276-284). The aperture 405 or recessadapted to accept the protruding coil (and the lower contacting portionof the core, if desired) is then formed in the PCB per step 504 (or thePCB acquired with such feature already present). Next, the core isadhered, mated to, or bonded to the PCB if required (step 506). Aspreviously described, such mating or bonding may be accomplished viaadhesive, silicone-based compounds, use of a “snap in” configuration,etc. Termination is then completed to the pads 450 disposed on the sideof the PCB opposite to the side on which the device 400 sits; i.e. thefree ends of the coil wire(s) are routed from the core assembly throughthe aperture (step 508) and terminated on the pads 450 (step 510).

Additionally, in another embodiment of the method, the coil 404 may bepre-positioned within the aperture (and optionally terminated to thepads 450 first) before the core elements 402 a, 402 b are “sandwiched”around the coil, and adhered to one another and/or the PCB 403.

Other Embodiments

Referring now to FIGS. 6 a and 6 b, yet another embodiment of the“formerless” inductive device of the present invention is described. Asshown in FIG. 6 a, this device 600 includes a core assembly 602 with twocore elements 602 a, 602 b and is generally similar to those previouslydescribed with respect to FIGS. 2 a-2 c, yet instead of using a headerto terminate the windings of the core, the windings 606 are terminatedto a substrate 604 such as a PCB. In the illustrated configuration, theterminal ends of the windings 606 are soldered to the pads 609 or tracesof the substrate 604 (which may be disposed on the upper and/or lowersurfaces of the substrate 604); however, welding (such as using standardelectronics welding techniques known to those of ordinary skill) may besubstituted if desired.

A conventional PCB section is chosen as the substrate in the illustratedembodiment for low cost; i.e., such PCBs are ubiquitous inmanufacturing, and have very low per unit costs since, inter alia, manycan be formed simultaneously.

The device 600 of FIG. 6 a also comprises an interface element 608 whichelectrically separates and mechanically locates the core 602 andwindings 606 on top of the substrate 604. The interface element 608 ofthe present embodiment is formed of a polymer (e.g., low cost plastic)fabricated using injection, transfer, or other common moldingtechniques, although other materials and formation techniques may besubstituted if desired. The substrate 604 optionally includes one ormore apertures 611 which cooperate with corresponding pins 612 on theinterface element underside which permit registration of the interfaceelement 608, although other means may be used to mechanically align thedevice 600 with respect to the substrate 604. For example, the edgefeatures 614 that cooperate with the substrate edges 616 (also shown inFIG. 6 a) may be used alone or in conjunction with the aforementionedapertures/pins to provide the desired alignment.

In yet another embodiment (FIG. 6 c), the lower portion of each of thecore elements are selectively extended to eliminate the cost and laborassociated with the interface element 608 of the embodiment of FIG. 6.Specifically, one variant uses two core halves 622 a, 622 b each with anextended skirt or lower portion 625 adapted to receive the substrate604, the core halves each with individually formed (or cut) apertures627 through which the winding conductors are routed, thereby allowingtermination of the winding ends to the substrate 604. The lower portionof the core hence provides the mechanical registration otherwiseprovided by the interface element 608 of the embodiment of FIG. 6 a.Alternatively other means for providing the desired mechanical alignmentmay be used, such as forming or machining the core portions 622 a, 622 bwith one or more small alignment pins that cooperate with aperturesformed on the substrate 604.

In another variant (FIG. 6 d), a plurality (e.g., eight) of perforationsor apertures 630 are formed in the substrate 604, with the insulatedconductors routed through the apertures 630 to contact pads or traces632 on, e.g., the bottom of the substrate. These contact pads or traces,or others in electrical communication therewith, act as an electricalinterface to the parent device (e.g., motherboard).

In still another embodiment (FIGS. 6 e and 6 f), the substrate 604 ispartly recessed into the bottom portion of the core elements 602 a, 602b. The winding leads (not shown) can then be routed either out throughthe gap 650 formed on the sides between the core elements and thesubstrate, through apertures formed in the substrate, or even directlyonto contacts or pads on the substrate upper surface under the winding(i.e., within the footprint” of the core). The substrate 604 may also beoutfitted with electrical terminals of the type well known in the art ifdesired, such as by adhering them directly to the substrate, orinserting them through apertures formed in the substrate.

It will be further appreciated that although described in the context ofa single inductive device, the techniques described above can also bereadily extended to multi-inductor devices such as those of FIG. 3. Forexample, multiple devices 600 of the type shown in FIGS. 6 a-6 f can bemated to a common substrate 604 and interface element 608, such as inthe “row” configuration of FIG. 3, or alternatively in another pattern(such as e.g., in an rectangular or square array). Myriad otherconfigurations will be recognized by those of ordinary skill given thepresent disclosure.

It will be recognized that while certain aspects of the invention aredescribed in terms of a specific sequence of steps of a method, thesedescriptions are only illustrative of the broader methods of theinvention, and may be modified as required by the particularapplication. Certain steps may be rendered unnecessary or optional undercertain circumstances. Additionally, certain steps or functionality maybe added to the disclosed embodiments, or the order of performance oftwo or more steps permuted. All such variations are considered to beencompassed within the invention disclosed and claimed herein.

While the above detailed description has shown, described, and pointedout novel features of the invention as applied to various embodiments,it will be understood that various omissions, substitutions, and changesin the form and details of the device or process illustrated may be madeby those skilled in the art without departing from the invention. Theforegoing description is of the best mode presently contemplated ofcarrying out the invention. This description is in no way meant to belimiting, but rather should be taken as illustrative of the generalprinciples of the invention. The scope of the invention should bedetermined with reference to the claims.

1. An electronic assembly, comprising: three or more shaped ferrous coreelements mated to one another in a substantially side-by-side fashion,said mated shaped ferrous core elements forming a plurality of windingchannels, each winding channel having a respective aperture associatedtherewith; a bonded wire winding having a plurality of turns anddisposed at least partly within at least one of said channels, saidwinding further comprising at least two ends which are routed throughsaid respective aperture; and a termination element comprising aplurality of electrically conductive terminals associated therewith,said plurality of electrically conductive terminals adapted for matingto corresponding electrical interfaces disposed on a printed circuitboard, said at least two ends of said winding being in electricalcommunication with ones of said terminals; wherein said at least one ofsaid channels associated with said bonded wire winding includes noformer or bobbin for said bonded wire winding; and wherein said bondedwire winding does not protrude below a bottom surface of saidtermination element.
 2. The assembly of claim 1, wherein each of saidthree or more shaped ferrous core elements comprises a ferrite ER-typecore element having a substantially circular center post.
 3. Theassembly of claim 2, wherein said termination element is bonded to atleast one of said plurality of shaped ferrous core elements using anadhesive.
 4. The assembly of claim 3, wherein said substantiallyside-by-side fashion includes a face-to-face mating interface, and atleast one other type of mating interface.
 5. The assembly of claim 4,wherein at least a portion of said plurality of electrically conductiveterminals comprises a substantially circular cross-section.
 6. Theassembly of claim 4, wherein said printed circuit board furthercomprises a signal interface to a broadband data connection.
 7. Theassembly of claim 6, wherein said printed circuit board furthercomprises an electronic circuit that, in combination with a plurality ofinductive devices formed using said three or more shaped ferrous coreelements, is compliant with a DSL configuration or service.
 8. Theassembly of claim 7, wherein said bonded wire winding comprises multiplewindings bonded into a unitary physical structure.
 9. The assembly ofclaim 1, wherein said plurality of shaped ferrous core elements areganged together in an array.
 10. The assembly of claim 9, wherein saidplurality of shaped ferrous core elements are ganged together in amultiplicity of formations.
 11. A digital subscriber line (DSL)electronic assembly, comprising: a printed circuit board (PCB) having aplurality of inductive devices mounted thereon, said plurality ofinductive devices collectively comprising: a plurality of shaped ferrouscore elements mated to one another, said plurality of shaped ferrouscore elements forming at least one winding channel when so mated, saidplurality of shaped ferrous core elements also collectively forming atleast one aperture communicating with said at least one channel when somated; a bonded wire winding having a plurality of turns and disposed atleast partly within said at least one winding channel, said windingfurther comprising at least two ends which are routed through said atleast one aperture; and a mounting header, comprising: a body; a bottomsurface; and a plurality of electrically conductive terminals protrudingfrom said bottom surface of said mounting header and adapted for matingto traces disposed on a substantially planar surface of said PCB, saidat least two ends of said winding being in electrical communication withones of said terminals; wherein said bonded wire winding disposed atleast partly within said at least one winding channel includes no formeror bobbin for said winding.
 12. The assembly of claim 11, wherein saidbonded wire winding comprises multiple windings bonded into a unitaryphysical structure.
 13. The assembly of claim 12, wherein said pluralityof shaped ferrous core elements are ganged together in an array.
 14. Theassembly of claim 13, wherein said plurality of shaped ferrous coreelements are ganged together in a multiplicity of formations.
 15. Theassembly of claim 14, wherein substantially all of said plurality ofturns of said bonded winding are each bonded via an insulative coatingto adjacent ones of said winding turns.
 16. The assembly of claim 15,wherein said plurality of turns are bonded via a vacuum depositionprocess.
 17. The assembly of claim 11, wherein said plurality of shapedferrous core elements are mated to one another using at least oneface-to-face mating, and at least one other mating other then aface-to-face mating.
 18. A method of operating a digital subscriber line(DSL) electronic assembly, comprising: obtaining a printed circuit board(PCB) having a plurality of inductive devices mounted thereon, saidplurality of inductive devices comprising: a plurality of shaped ferrouscore elements mated to one another, said plurality of shaped ferrouscore elements forming at least one winding channel when so mated, saidplurality of shaped ferrous core elements also collectively forming atleast one wire routing aperture communicating with said at least onewinding channel with a first portion of said plurality of shaped ferrouscore elements mated in a face-to-face disposition and a second portionof said plurality of shaped ferrous core elements mated in nonface-to-face disposition; a bonded wire winding having a plurality ofturns and disposed at least partly within said at least one windingchannel, said winding further comprising at least two ends which arerouted through said at least one wire routing aperture; and a mountingheader for said plurality of shaped ferrous core elements, said mountingheader comprising: a body supporting said plurality of shaped ferrouscore elements; a bottom surface; and a plurality of electricallyconductive terminals protruding from said bottom surface of saidmounting header and adapted for mating to said printed circuit board,said at least two ends of said winding being in electrical communicationwith ones of said terminals; wherein said bonded wire winding disposedat least partly within said at least one winding channel includes noformer or bobbin for said winding; and disposing said printed circuitboard comprising said plurality of inductive devices in a DSL equipmentapparatus so as to operative therein.
 19. The method of claim 18,wherein said DSL equipment apparatus comprises DSL central officeequipment.
 20. The method of claim 18, wherein said DSL equipmentapparatus comprises DSL home premises equipment.
 21. A digitalsubscriber line (DSL) apparatus, comprising: at least one DSL modemapparatus; and an electronic assembly in signal communication with saidmodem apparatus, the assembly comprising: a plurality of shaped ferrouscore elements mated to one another in a substantially side-by-sidefashion, said mated shaped ferrous core elements forming a plurality ofwinding channels, each winding channel having a respective apertureassociated therewith; a bonded wire winding having a plurality of turnsand disposed at least partly within at least one of said channels, saidwinding further comprising at least two ends which are routed throughsaid respective aperture; and a termination element comprising aplurality of electrically conductive terminals associated therewith,said plurality of electrically conductive terminals adapted for matingto corresponding electrical interfaces disposed on a printed circuitboard associated with said DSL apparatus, said at least two ends of saidwinding being in electrical communication with ones of said terminals;wherein said at least one of said channels associated with said bondedwire winding includes no former or bobbin for said bonded wire winding;and wherein said bonded wire winding is disposed substantially above abottom surface of said termination element.
 22. The apparatus of claim21, wherein said DSL apparatus comprises DSL central office equipment.23. The apparatus of claim 21, wherein said DSL apparatus comprises DSLconsumer premises equipment.